A REPORT ON INDUSTRIAL VISIT

RINL VISAKHAPATNAM STEEL PLANT

SUBMITTED BYk.Sai Dinesh 1225113222 Mba-b

About the visit :

We have been to VISAKHAPATNAM STEEL PLANT on 15th FEB 2014, and this is our second industrial visit in this academic year. Visakhapatnam steel plant is located 15 Kms to the South West of the Visakhapatnam Port. It lies between the Northern boundary of the National Highway No. 5 from Madras to Kolkata and 7 Kms to the South West of Howrah Madras railway line. Visakhapatnam steel plant is the only shore based integrated steel plant in our country where Smt. Indira Gandhi laid the foundation stone fulfilling the long cherished dream of the people of Andhra Pradesh. Visakhapatnam steel plant is the most advanced steel producer in India with the help German and Soviet technology. Its products had been rated best in world market. Almost 80% of its income earns from export of steel to Japan, Germany, USA, Singapore, Dubai, Australia, South American countries. To achieve goals plant was characterized as one having Minimum manpower, better discipline and a good team work. The blue print of Visakhapatnam Steel Plant described the plant as the most modern Steel plant employing new technologies - very best in the industry with latest instrumentation and introduction of computerization on large scale.

VISION:
. To be a continuously growing world class company we shall

Harness our growth potential and sustain profitable growth. Deliver high quality and cost competitive products and be the first choice of customers. Create an inspiring work environment to unleash the creative energy of people. Achieve excellence in enterprise management. Be respected corporate citizen, ensure clean and green environment and develop vibrant communities around us

MISSION:

To attain 20 Mt liquid steel capacity through technological up-gradation, Operational efficiency and expansion; augmentation of assured supply of raw materials; to produce steel at international Standards of Cost & Quality; and to meet the aspirations of stakeholders.

Process :

Coke Oven and Coke Chemicals Plants: Coke oven plant consists of three coke oven batteries of 67 ovens each with useful coke chamber volume of 41.6 cubic meters. Each battery is of 7 meters height. It produces coke in the sizes of 25 to 70 mm which meet the coke requirement of the Blast furnaces. The annual capacity of the three batteries is 2.261 mt. During production operation the CO gas (carbon monoxide) generated is used in the Coke chemical plants to extract different by products like Benzol, Ammonium Sulphate, Tar products etc. After extracting all the valuable products the remaining gas is used as a energy source. Sinter Plant: There are two sinter machines each of 312 sq.mt grate area. Here iron ore fines, coke breeze, lime stone, dolomite are mixed together to from the agglomerated mass, called gross sinter which is used in Blast Furnaces as the primary input. The annual production capacity is 5.256 mt. Blast Furnace (BF): There two Blast Furnaces named "GODAVARI" and "KRISHNA", each of 3200 cubic meter useful volume. Here hot metal is produced from the raw materials like iron ore (Lump), sinter, coke and limestone etc. The annual capacity of this facility is 3.4 mt. From molten hot metal pig iron / steel is produced. Steel melting shop: There are three nos. of LD converters each of 133 cubic meters with a capacity to produce 3 mt of liquid steel. The production capacity of a plant is its capacity to produce liquid steel. VSP is a 3 mt plant. SMS also has six number of four strand continuous casting machines to produce blooms. 2.82 mt of blooms can be cast annually. In this shop hot metal from BF is received in the mixer, kept for _ temporary storage and transferred to converter where charging takes place in presence of 99.5% pure oxygen. After Argon rinsing the molten steel is moved from here to the six strand continuous casting machines. Blooms are formed which form the input material for the mills. Blooms are also taken as input to small steel making industries. Rolling Mills: There are three rolling mills in VSP. 1. Light & Medium merchant mills: It includes the billet mill and bar mill. It has a two strand rolling mill. It produces billets, bars and structures. The annual capacity is 1.857 mts of billets and 7.1 mt of bars & structures. 2. Wire Rod mill: It is a high speed four strand continuous mill. The mill is designed to produce wire rods in plain rounds and ribbed bars (5.5 to 12.7 mm diameter). The annual capacity of wire rods production is 0.8 mt. 3. Medium and Merchant mill : This mill produce squares 12 to 65 mm, flats 30 to 150 mm, channels and angles etc. This mill has an annual capacity of 0.85 mt of structures, bars and angles. Coke is manufactured by heating of crushed coking coal (below 3mm) in absence of air at temperature of 1000 /C and above for about 16 to 18 hours. A coke oven comprises of two hollow chambers namely coal chamber and heating chamber. In the heating chamber a gaseous fuel such as Blast Furnace Gas, Coke Oven Gas etc. is burnt. The heat so generated is conducted through the

common wall to heat & carbonize the Coking Coal placed in the adjacent coal chamber. Number of ovens built in series one after the other form a Coke Oven Battery. At VSP there are three coke Oven Batteries, 7metre tall and having 67 Ovens each. Each oven is having a volume of 41.6cu.metre & can hold up to 31.6 Ton of dry coal charge. The Carbonization takes place at 1000-1050c in absence of air for 16-18 hours. Coal charging done in sequence operation with the charging car. At first 14 T of coal charging done through c/s hatch, after that 12 T of coal charging done through p/s hatch, after completion of c/s and pusher side, 8T of coal charging done through middle hatch of the oven. After this charging, coal heaps are formed in the oven, so for uniform coal level, leveling is done with the pusher car during middle charging. So that by leveling, coal level becomes uniform in oven. So that during leveling excessive coal comes out through door window. This coal is called spillage coal. The spillage coal collected in the spillage bunker in the pusher car during leveling. This spillage coal in the pusher car bunker is dumped in a bunker situated on pusher side platform in 5meter level of coal tower area .This coal is transported in a movable bucket to the bunker situated in the oven top, from which charging car collects the coal, and again this coal is charged into the oven. The equipment which performs the above operation is called skip hoist. Since the time of commission this has been working in manual mode with relay logic. This was put on to auto mode on 23 July 2005, with plc. One vibrator is also provided to lower bunker which is situated in coal tower at 5meter level. This vibrator works in manual and also in Auto mode. Red Hot Coke is pushed out of the oven and sent to Coke Dry Cooling Plants (CDCP) each having 4 cooling chambers. The capacity of each cooling chamber is 50-52 TPH. Nitrogen gas is used as the Cooling medium .The heat recovery from nitrogen is done by generating steam to run two back pressure turbines to produce 7.5MW power each. The Coal chemicals such as Benzole (& it products), Tar (&its products), Ammonium Sulphate etc. are extracted in Coal Chemical Plant from C.O. Gas. After recovering the coal chemicals the gas is used for heating up of Coke Ovens. Workplace conditions: safety equipment is provided but management is not insisted workers to use them. So most of the employees are not using the safety equipment. Working conditions is too worse there are many possibilities of accidents. But the whole they fallow a process to which reducing the wastage and get greater productivity.

Conclusion :
It is a great opportunity for us to visit an industry like STEEL PLANT, the visit was very informative and it provided a huge technical knowledge. We were allowed at every plant within the industry, the steel plant has many units processing at different levels. We have talked with `the managers and supervisors who shared their experiences with us. We got to know about the job satisfaction, work-life balance and also the mental and physical stress laid down by the employees in the industry.